Yarn and Method of Manufacturing Thereof

ABSTRACT

Embodiments of the present invention are directed to a tri-core yarn including a core including an elastomeric filament, a first cover, and a second cover, and a fiber sheath covering the core, wherein the first cover and the second cover are each wrapped around the elastomeric filament.

BACKGROUND 1. Field

Embodiments of the present invention relate to yarn and a method ofmanufacturing thereof.

2. Description of the Related Art

Composite elastic yarns are well-known. Generally, conventionalcomposite yarns include an elastomeric filament or elastomeric fiberconstituting a core covered by a relatively inelastic fibrous orfilamentary sheath. Particularly, stretch fabrics including elasticcomposite yarn have recently seen increased popularity in the fashionand textiles markets due to their comfort, versatility, and durability.

A conventional composite yarn has been made, wherein a single elasticfiber (as a core) runs through a sheath of hard fibers. In this case, an“elastomeric fiber” is a continuous filament which has a breakelongation in excess of 100% independent of any crimp and which whenstretched to twice its length, held for one minute, and then released,retracts to less than 1.5 times its original length within one minute ofbeing released. Such fibers include, but are not limited to, rubbers,spandex or elastane, polyetheresters, and elastoesters.

To produce a composite core spun yarn, a single core spinning attachmentis attached to a spinning apparatus. In one example, the attachment is ametal plate bent to a shape suited for its purpose. The attachment maybe coupled to the spinning apparatus such that a relative position of aroving, i.e., a strand of staple fibers in an intermediate state betweensliver and yarn which are provided to be a continuous stream of staplefibers fed into the apparatus and the core filament may be kept constantat all times. Further, the attachment may include a porcelain guide thatfeeds the core filament at a precise position with respect to the frontdrafting rollers. The attachment also may have a pre-tensioner to allowvariation of the input tension of the core filament.

However, conventional composite yarns do not provide all of the desiredcharacteristics, namely, easy stretch, high recovery, and low shrinkageperformance. Particularly, although these yarns provide some elasticityfor stretch fabrics, the yarns exhibit poor recovery, and may result insaggy or baggy clothing over time.

More recently, yarns being spun with two sets of elastic yarns in thecore have been introduced, so called “dual core” yarns. These “dualcore” yarns 1 (see FIG. 1) include a first elastic yarn 2 and a secondelastic yarn 3 which are substantially parallel to each other and afiber sheath 5 is used to cover the two elastic yarns 2, 3. However, torun two sets of different elastic core fibers (i.e., the first elasticyarn 2 and the second elastic yarn 3), special and costly attachmentsare required. For example, referring to FIG. 1, two separate fiber draftdevices may need to be installed on a core spinning apparatus. The corespinning apparatus includes two separate core filaments (i.e., the firstelastic yarn 2 and the second elastic yarn 3) respectively accommodatedon a respective bobbin 4, 6. The bobbins 4, 6 are respectivelypositioned on feed rollers 8, 9, and are each controlled by a separatefiber draft device. The two elastic core fibers 2, 3 are then fed to onedraft roller 7. Further, two attachments, such as the one describedabove, may be required. Even further, because the two elastic corefibers 2, 3 typically have different draft ratios, the tensioning of thetwo elastic core fibers 2, 3 may require additional programming orsoftware to facilitate and drive the separate fiber draft devices.

Accordingly, dual core yarns result in an exponential increase in thecost of stretch woven fabrics. Further, the dual core yarns aresusceptible to slippage of one elastomeric yarn, which is inserted at ahigher draft relative to the other core yarn, which further raises costsof fabrication, may have adverse effects on elasticity, recovery, andmay result in sagging.

Alternative to core spun yarns, covered yarns have also been used. In acovered yarn, one or more polyester or nylon filaments are wound aroundan elastomeric core. However, these covered yarns often have a harsh,synthetic feel, and therefore may be disfavored by a garment wearer.

In general, it is desirable for stretch fabrics to be comfortable for awearer, to have stretchability, and to have high recoverability, suchthat the garment returns to the same or substantially the same shapeafter stretching. Without high recoverability, a garment may sag orbecome baggy after long-term or repeated wear. Additionally, it isdesirable for stretch fabrics to be manufactured economically to keepthe price reasonable, particularly if the economically provided fabricsalso exhibit improved performance.

SUMMARY

Accordingly, there is a desire for a yarn and a method of manufacturinga yarn that reduces manufacturing costs while providing a yarn withcomfort, stretch, and recovery characteristics. Particularly, there is adesire for a multiple fiber core yarn that is core spun to achieve suchcharacteristics.

A yarn according to one or more embodiments of the present inventionincludes a single core that is comfortable, provides high stretch, goodrecovery, low growth, and prevents or reduces the likelihood of slippingand/or creating stretch voids.

In one or more embodiments of the present invention, a tri-core yarnincludes a core including an elastomeric filament, a first cover, and asecond cover, and a fiber sheath covering the core, wherein the firstcover and the second cover are each wrapped around the elastomericfilament.

In some embodiments, the first cover may be wrapped in a first directionand the second cover may be wrapped in a second direction.

In some embodiments, the elastomeric filament, the first cover, and thesecond cover may be twisted together.

In some embodiments, the first cover and the second cover may bedifferent materials.

In some embodiments, the elastomeric fiber may be in a range of about 10denier to about 300 denier.

In some embodiments, the first cover may include polyester or nylon.

In some embodiments, the first cover may be partially oriented yarn orfully drawn yarn.

In some embodiments, the first cover may be in a range of about 10denier to about 600 denier.

In some embodiments, the core may be in a range of about 10 denier to600 denier.

In some embodiments, the fiber sheath may include cotton, polyester,viscose, rayon, modal, lyocell, cupro, nylon, acrylic, wool, linen,hemp, ramie, and/or polyethylene.

In some embodiments, the first cover yarn may be wrapped around theelastomeric filament and the second cover yarn may be wrapped around thefirst cover yarn.

According to one or more embodiments of the present invention, a methodof manufacturing yarn includes covering an elastomeric filament with afirst cover yarn and a second cover yarn to form a core andcore-spinning the core to add a fiber sheath.

In some embodiments, the covering of the elastomeric filament mayinclude wrapping the first cover yarn around the elastomeric filament ina first direction and wrapping the second cover yarn around theelastomeric filament in a second direction.

In some embodiments, the covering of the elastomeric filament mayinclude intermingling or air-covering the elastomeric filament with thefirst cover yarn and the second cover yarn.

In some embodiments, the covering of the elastomeric filament mayinclude aligning the elastomeric filament, the first cover yarn, and thesecond cover yarn and twisting the elastomeric filament, the first coveryarn, and the second cover yarn together.

According to one or more embodiments of the present invention, a stretchfabric includes a yarn, and the yarn includes a core including anelastomeric filament, a first cover; and a second cover; and a fibersheath covering the core, wherein the first cover and the second coverare each wrapped around the elastomeric filament.

In some embodiments, a weft and a warp of the fabric may include theyarn.

In some embodiments, the fabric includes plain, poplin, twill, oxford,dobby, sateen and/satin fabric.

In some embodiments, the stretch fabric may be stretched to between 10%and 100% of its original size in a warp direction.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and aspects of embodiments of the presentinvention will be better understood by reference to the followingdetailed description, when considered in conjunction with theaccompanying figures. Like numbers are used throughout the figures toreference like features and components.

FIG. 1 is a schematic view of a conventional dual core yarn coveringapparatus for preparing a core.

FIG. 2 is a side view of a partially wrapped tri-core yarn according toone or more embodiments of the present invention.

FIG. 3 is a cross-sectional view of the tri-core yarn of FIG. 2 takenalong the line 3-3 of FIG. 2.

FIG. 4 is a schematic view of a tri-core yarn covering apparatus forpreparing a core according to one or more embodiments of the presentinvention.

FIG. 5 is a schematic view of a tri-core yarn spinning apparatus forpreparing a completed tri-core yarn according to one or more embodimentsof the present invention.

FIG. 6 is a side view of a partially wrapped yarn according to one ormore embodiments of the present invention.

FIG. 7 is a side view of a core of the yarn of FIG. 6.

FIG. 8 is a schematic view of a covering apparatus for preparing thecore of FIG. 7.

FIG. 9 is a side view of a core of a yarn according to one or moreembodiments of the present invention.

FIG. 10 is a cross-sectional view of the core of FIG. 9 and a sheath.

FIG. 11 is a schematic view of an apparatus for covering the core ofFIG. 9.

FIG. 12 is a side view of a core of a yarn according to one or moreembodiments of the present invention.

FIG. 13 is a cross-sectional view of the core of FIG. 12.

FIG. 14 is a schematic view of an apparatus for covering the core ofFIG. 12.

DETAILED DESCRIPTION

Embodiments of the present invention relate to a yarn including a singlecore having an elastomeric fiber that is covered by one or more coverfibers, and then core spun inside a sheath of hard fibers. In otherwords, the yarn includes a multiple-fiber core, for example, a corehaving two, three, or more fibers, such multiple fiber core then beinglocated within a sheath of fibers core spun to produce the yarn.

Despite the yarn having a core including multiple fibers, which wouldusually each require separate attachment to the spinning apparatus,embodiments of the present invention include such multiple fiber coresthat can be produced without requiring a separate attachment for eachcore yarn. Rather, the fibers that make up the core may first becombined together to produce a covered core yarn, whereby one, two, ormore cover fibers are combined with an elastomeric fiber, for example,by wrapping the cover fiber(s) around the elastomeric fiber.

After the covered core yarn has been produced, the covered core yarn canthen be core spun with the sheath fibers to produce the final yarn. Eventhough the covered core yarn contains multiple fibers, it effectivelyforms a single strand that can be fed into a spinning apparatus to thenbe core spun with the sheath fibers.

As such, traditional single core spinning equipment may be used tofabricate the yarn. In other words, while conventionally produced corespun yarns having multiple core fibers may be known, as noted above,such yarns typically require a separate attachment for each of the corefibers. However, embodiments of the present invention provide for themanufacture of multiple-fiber core spun yarns that are producible byusing a single core spinning apparatus.

Further, while core spun yarns are known having two core fibers,embodiments of the present invention provide for a core spun yarn thathas at least three core fibers. Additionally, such a three core (ortri-core) spun yarn can also be produced on an apparatus having only asingle core spinning attachment rather than requiring multiple spinningattachments.

The drawings depict some example embodiments for illustrative purposesonly, and it will be apparent that modifications may be made withoutdeparting from the spirit and scope of the invention, and also that thepresent invention may be used in other applications in the same orsimilar fields. Moreover, the figures contained in this application arenot necessarily drawn to scale and various features may be exaggerated.

Referring now to FIGS. 2-5, a composite yarn (or a “tri-core yarn”) 10includes a core 12 that is covered by a fiber sheath 14. The core 12 maybe interchangeably referred to herein as a “covered core yarn.”

In one or more embodiments, the covered core yarn 12 includes anelastomeric fiber (or filament) 16, a first cover (or first cover yarn)18, which is wrapped around the elastomeric fiber 16, and a second cover(or second cover yarn) 20, which is wrapped around the elastomeric fiber16 and the first cover 18. The covered core yarn 12 is then covered bythe fiber sheath 14 to form the tri-core yarn 10. The elastomeric fiber16 may be in a range of between about 10 denier to about 300 denier. Thefirst cover 18 and the second cover 20 may include a rigid or slightlyelastic yarn, such as partially oriented yarn (“POY”), drawn texturedyarn (“DTY”) and/or fully drawn yarn (“FDY”), and may be in a range ofbetween about 10 denier to about 600 denier. The first cover 18 may bewrapped around the elastomeric fiber 16 in a first direction (e.g., aclockwise direction) and the second cover 20 may be wrapped around theelastomeric fiber 16 is a second direction (e.g., a counterclockwisedirection). It will be appreciated that although the figures show thefirst cover 18 tightly wrapped around the elastomeric fiber 16 such thatthe second cover 20 and the elastomeric fiber 16 do not contact eachother, in some embodiments, the second cover 20 and the elastomericfiber 16 may contact each other. For example, when the first cover 18 iswound such that openings or gaps are formed between each winding of thefirst cover 18, when the second cover 20 is wrapped around the firstcover 18 and the elastomeric fiber 16, the second cover 20 may contactthe elastomeric fiber 16.

As shown in FIG. 4, a covering apparatus 30 is provided to produce thecovered core yarn 12 having the first cover 18 and the second cover 20.In one embodiment, the covering apparatus 30 includes a first core yarnbobbin 32 rotatably mounted on a first support roller 44. The first coreyarn bobbin 32 accommodates the elastomeric fiber 16, which is unwoundfrom the first core yarn bobbin 32 to provide a supply of a first corefiber. The elastomeric fiber 16 extends from the first core yarn bobbin32 over a first feed roller 34.

The covering apparatus further includes a first hollow bobbin 36 havinga channel 52 extending along a longitudinal axis therethrough and afirst spindle 54 arranged between the first hollow bobbin 36 and thefirst feed roller 34. The first hollow bobbin 36 includes a supply of afirst wrapping fiber 18 wound thereon. The first hollow bobbin 36 havingthe first wrapping fiber 18 wrapped around it is located at a positionbetween the first feed roller 34 and a second hollow bobbin 50 and isrotatable about its longitudinal axis. The first wrapping fiber 18extending between the first feed roller 34 and the second hollow bobbin50 extends through the channel 52 of the first hollow bobbin 36.

The first spindle 54 may generate (or control) rotational speed and awrapping ratio of the elastomeric fiber 16 and the first wrapping fiber18. When the first hollow bobbin 36 is rotated in a first direction (forexample, a clockwise direction), the first wrapping fiber 18 located onthe outside of the first hollow bobbin 36 is wrapped around theelastomeric fiber 16 exiting the channel 52 of the first hollow bobbin36, thereby forming an intermediate core 17. In one embodiment, thefirst wrapping fiber 18 is guided through a first ring guide 38 toensure that it is evenly and accurately wrapped around the elastomericfiber 16 to form the intermediate core 17.

The second hollow bobbin 50 and the first hollow bobbin 36 may havesubstantially the same structure. As such, the second hollow bobbin 50may have a channel 56 extending along a longitudinal axis therethrough,and includes a supply of a second wrapping fiber 20 wrapped thereon. Thesecond hollow bobbin 50 having the second wrapping fiber 20 wrappedaround it is located at a position between the first hollow bobbin 36and a second feed roller 40, and is rotatable about its longitudinalaxis.

The second wrapping fiber 20 extending between the first hollow bobbin36 and the second feed roller 40 extends through the channel 56 of thesecond hollow bobbin 50.

A second spindle 58 may be arranged between the second hollow bobbin 50and the second feed roller 40 and may generate (or control) rotationalspeed and a wrapping ratio of the intermediate core 17 and the secondwrapping fiber 20. When the second hollow bobbin 50 is rotated in asecond direction (for example, a counterclockwise direction), the secondwrapping fiber 20 located on the outside of the second hollow bobbin 50is wrapped around the intermediate core 17. Particularly, the secondwrapping fiber 20 is guided through a second ring guide 60 to ensurethat it is evenly and accurately wrapped around the intermediate core 17to produce the three-fiber covered core yarn 12 including theelastomeric fiber 16, the first wrapping fiber 18, and the secondwrapping fiber 20.

In some embodiments, the second hollow bobbin 50 and the first hollowbobbin 36 are rotated in different (or opposite) directions, such thatthe first wrapping fiber 18 is wrapped around the elastomeric fiber 16in one direction and the second wrapping fiber 20 is wrapped around theelastomeric fiber 16 in a different direction.

Referring to FIG. 5, a core spinning apparatus 70 is provided to producethe tri-core yarn 10 using the covered core yarn 12. In someembodiments, the core spinning apparatus 70 includes a first core yarnbobbin 72 rotatably mounted on a first feed roller 74. The covered coreyarn 12 is wound around the first core yarn bobbin 72 to provide a coreof the yarn 10. The covered core yarn 12 extends from the first coreyarn bobbin 72, around a first feed roller 76 and to a second feedroller 78. The covered core yarn 12 may include three yarns or filaments(e.g., the elastomeric fiber 16, the first cover 18, and the secondcover 20), as described above.

The core spinning apparatus 70 further includes a roving 80 having afiber (e.g., cotton) 82 wound thereon. The cotton 82 is wound around theroving 80 and extends from the roving 80 to a third feed roller 84. Thecotton 82 and the covered core yarn 12 are both fed through the secondfeed roller 78 and the cotton 82 is wrapped around the core 12 to formthe sheath 14 around the covered core yarn 12, and thereby forming thetri-core yarn 10. The tri-core yarn 10 is then wrapped around a skein86.

The fiber sheath 14 may include cotton, polyester, viscose, rayon,modal, lyocell, cupro, nylon, acrylic, wool, linen, hemp, ramie,polyethylene, or any combination thereof.

It will be appreciated that the covered core yarn 12 may provideelasticity, yet may be used on a traditional bobbin in a traditionalcore spinning process or a ring spinning process. Because theelastomeric fiber 16 of the covered core yarn 12 is covered, the coveredcore yarn 12 may be used on a traditional bobbin, without the need for asecond, separate elastomeric fiber 16 in the core, and the covered coreyarn 12 may easily receive the fiber sheath 14 during spinning. As such,fabrication of the composite yarn 10 may be simplified by using thecovered core yarn 12, and manufacturing costs may be significantlyreduced, while still providing elasticity and recovery. Further, bycovering the elastomeric fiber 16 in the covered core yarn 12, theelastic qualities of the elastomeric fiber 16 may be provided to thecovered core yarn 12, but the covered core yarn 12 is capable ofreceiving the fiber sheath 14.

The covered core yarn according to embodiments of the present inventionmay include one wrapping fiber, or may include two or more wrappingfibers. For example, as illustrated in FIGS. 6 and 7, in someembodiments a composite yarn 10′ may have a covered core yarn 12′including an elastomeric fiber 16′ and a first cover 18′. Theelastomeric fiber 16′ may be in a range of between about 10 denier toabout 300 denier. The first cover 18′ may include a rigid or slightlyelastic yarn, such as polyester and/or nylon yarn, and may be POY, DTY,and/or FDY, and may be in a range of between about 10 denier to about600 denier.

As shown in FIG. 8, a covering apparatus 130 is provided to produce thecovered core yarn 12′. In one embodiment, the covering apparatus 130includes a first core yarn bobbin 132 rotatably mounted on a firstsupport roller 144. The elastomeric fiber 16′ is wound around the firstcore yarn bobbin 132 to provide a supply of a first core fiber. Theelastomeric fiber 16′ extends from the first core yarn bobbin 132 over afirst feed roller 134.

The covering apparatus further includes a hollow bobbin 136 having achannel 152 extending along a longitudinal axis therethrough and aspindle 154 arranged between the hollow bobbin 136 and the first feedroller 134. The hollow bobbin 136 includes a supply of a first wrappingfiber 18′ wound thereon. The hollow bobbin 136 having the first wrappingfiber 18′ wrapped around it is located at a position between the firstfeed roller 134 and a second feed roller 140 and is rotatable about itslongitudinal axis. The first wrapping fiber 18′ extending between thefirst and second feed rollers 134, 140 extends through the channel 152of the hollow bobbin 136.

The spindle 154 may generate (or control) rotational speed and awrapping ratio of the elastomeric fiber 16′ and the first wrapping fiber18′. When the hollow bobbin 136 is rotated, the first wrapping fiber 18′located on the outside of the hollow bobbin 136 is wrapped around theelastomeric fiber 16′ exiting the channel 152 of the hollow bobbin 136.Particularly, the first wrapping fiber 18′ is guided through a ringguide 138 to ensure that it is evenly and accurately wrapped around theelastomeric fiber to produce the two-fiber covered core yarn 12′including the elastomeric fiber 16′ and the first wrapping fiber 18′.

The covered core yarn 12′ is then fed over the second feed roller 140and is wound around a winding bobbin 142 which is rotatably mounted on asecond support roller 146. The two-fiber covered core yarn 12′ can thenbe used as the core of the composite yarn 10′. For example, the coveredcore yarn 12′ may be used in the core spinning apparatus 70 describedabove with respect to FIG. 5 to produce the composite yarn 10′.

As yet another example, referring to FIGS. 9-14, a composite yarn mayinclude a covered core yarn including an elastomeric fiber and aplurality of cover yarns. The elastomeric fiber may be in a range ofbetween about 10 denier to about 300 denier. The plurality of coveryarns may be twisted, intermingled, or entangled by winding or using anair jet to cover the elastomeric fiber. The cover yarns may include arigid or slightly elastic yarn, such as polyester and/or nylon yarn, andmay be POY, DTY, and/or FDY, and may be in a range of between about 10denier to about 600 denier.

In one or more embodiments, referring to FIGS. 9-11, a composite yarn10″ may have an elastomeric fiber 16″, a first cover 18″, and a secondcover 20″ which are aligned and twisted together to form a twist coveredcore yarn 12″.

Referring to FIG. 11, the covered core yarn 12″ may be prepared using atwist covering apparatus 200. In one embodiment, the twist coveringapparatus 200 includes a bobbin 202 rotatably mounted on a supportroller 204. The elastomeric fiber 16″, the first cover 18″, and thesecond cover 20″ are each wound in parallel around the bobbin 200 (e.g.,to form semi-parallel yarn).

The elastomeric fiber 16″, the first cover 18″, and the second cover 20″are then guided through a nozzle 206 and into a twisting pot 208. Forexample, the elastomeric fiber 16″, the first cover 18″, and the secondcover 20″ may be fed through a channel 210 extending along alongitudinal axis of a skein 212 inside the twisting pot 208, and aspindle 214 may be arranged between the skein 212 and the support roller204 to generate (or control) rotational speed of the elastomeric fiber16″, the first cover 18″, and the second cover 20″. The elastomericfiber 16″, the first cover 18″, and the second cover 20″ are then guidedthrough the channel 210 through an eye 218 at the end of a twisting arm216. Accordingly, the elastomeric fiber 16″, the first cover 18″, andthe second cover 20″ are twisted together to fore the composite core12″, which is then wound onto the skein 212.

As another example, in one or more embodiments, the covered core yarnmay include a plurality of cover yarns. For example, referring to FIGS.12-14, a composite yarn 10′″ may have an elastomeric fiber 16′″, and aplurality of cover yarns 19′″ which cover the elastomeric fiber 16′″ toform a covered core yarn 12′″.

Referring to FIG. 14, the covered core yarn 12′″ may be prepared usingan air covering apparatus 300. In one embodiment, the air coveringapparatus 300 includes a first bobbin 302 having the elastomeric fiber16′″ wound thereon, that is rotatably mounted on a first support roller304, a second bobbin 306 having one of the plurality of cover yarns 19′″wound thereon, that is rotatably mounted on a second support roller 310,and a third bobbin 308 having one of the plurality of cover yarns 19′″wound thereon, that is rotatably mounted on a third support roller 312.

The elastomeric fiber 16′″ is fed through a first draw roller 314 andthe cover yarns 19′″ are fed through a second draw roller 316. Theelastomeric fiber 16′″ and the cover yarns 19′″ are then fed into a stopmotion 318, which gathers the elastomeric fiber 16′″ and the cover yarns19′″ together. The gathered elastomeric fiber 16′″ and the cover yarns19′″ are then guided through additional rollers 320 to an air nozzle 322which intermingles the elastomeric fiber 16′″ and the cover yarns 19′″,thereby forming the covered core yarn 12′″, which is then wound onto abobbin 324.

The tri-core yarn 10 may be used for making various stretch fabricscapable of having weave patterns. For example, the tri-core yarn 10 maybe used for plain, poplin, twill, oxford, dobby, sateen, satin, andcombinations thereof, providing stretch that may vary from 10% to 100%in warp and/or weft direction. Further, the tri-core yarn 10, and theresulting stretch fabric, may have a natural hand feel.

The tri-core yarn 10 may be used for weft and/or for warp. The tri-coreyarn 10 used for warp can be the same as or different from the tri-coreyarn 10 used for weft in producing stretch fabric. The stretch fabricmay be weft stretch and/or bi-stretch.

As such, the tri-core yarn 10 is easily stretchable without overlyrestricting or constricting on a user, as is common with other fibershaving similar stretch characteristics, such as shapeware.

The tri-core yarn 10 according to embodiments of the present inventionmay have greater stretch and may provide improved stability. Inaddition, the tri-core yarn 10 may provide greater stretch with improvedrecovery and less shrinkage, while providing a wider width and thus alower cost.

Specific examples of composite yarns which are embodiments of thepresent invention are provided below. Additionally, data relating to thestretch, recovery, and shrinkage are provided for the listed examples aswell as comparison data for traditional composite yarns.

EXAMPLE 1

In Example 1, 70 denier FIBER J® (FIBER J is a registered trademark ofLubrizol Advanced Materials, Inc.) was used as the elastomeric fiber, 30denier nylon was used as the first wrapping fiber, and 30 denier nylonwas used as the second wrapping fiber to form a tri-core covered coreyarn.

The tri-core covered core yarn was then core spun using a single corespinning apparatus to produce a tri-core composite yarn. To produce afabric (Tri-Core Fabric 1), 21 (Ne 21/1) of this tri-core yarn was usedfor the weft, and 12 SB (Ne 12/1 slub) for the warp. The resultingcomposition of the Tri-Core Fabric 1 in Example 1 was 90% cotton, 7%nylon, and 3% spandex. This produced the Tri-Core Fabric 1 having awidth of 52.5 inches, and a weight before wash of 9.0 ounces per squareyard and a weight after wash of 10.2 ounces per square yard.

Using the Tri-Core Fabric 1 having the tri-core composite yarn describedabove, the Tri-Core Fabric 1 exhibited a stretch of 74%, recovery of85.6% 30 minutes after stretching, and 12-14% shrinkage.

In a similar trial of a dual-core yarn as is known in the art (aDual-Core Fabric 1), a dual-core yarn having a first core of 75 denierT400® (T400 is a registered trademark of Invista North America S.A.R.L.Corporation Luxembourg) and a second core of 40 denier LYCRA® (LYCRA isa registered trademark of Invista North America S.A.R.L. CorporationLuxembourg), were used. In particular, the Dual-Core Fabric 1 wasprepared with a warp of 12 SB and a weft of 21 of the dual-core yarndescribed above. The resulting composition of the Dual-Core Fabric 1 was90% cotton, 8% T400®, and 3% LYCRA®. This produced the Dual-Core Fabric1 having a width of 49.5 inches, and a weight before wash of 9.4 ouncesper square yard and 10.8 after wash ounces per square yard.

Using the Dual-Core Fabric 1 having the dual-core yarn described above,the Dual-Core Fabric 1 exhibited a stretch of 71%, recovery of 87.9% 30minutes after stretching, and 13-15% shrinkage. The pro-rated cost toprepare the Dual-Core Fabric 1 at a comparable width of 52.5 inches was14% higher than the cost to prepare the Tri-Core Fabric 1.

In a similar trial of single core yarn as is known in the art (aSingle-Core Fabric 1), a single-core yarn having a 70 denier LYCRA® corewas used. In particular, the Single-Core Fabric 1 was prepared with awarp of 14 Even and a weft of 21 with the 70 denier LYCRA® core. Theresulting composition of the Single-Core Fabric 1 was 97% cotton and 3%LYCRA®. This produced the Single-Core Fabric 1 having a width of 51inches, and a weight before wash of 8.5 ounces per square yard and 10.7after wash ounces per square yard.

Using the Single-Core Fabric 1 having the single core yarn describedabove, the Single-Core Fabric 1 exhibited a stretch of 82%, recovery of81.2% 30 minutes after stretching, and shrinkage of 22-24%. Thepro-rated cost to prepare the Single-Core Fabric 1 at a comparable widthof 52.5 inches was approximately 6% higher than the cost to prepare theTri-Core Fabric 1.

As demonstrated by the above results, the Single-Core Fabric 1 exhibited76% more shrinkage for 15% more stretch and with decreased recoverycharacteristics as compared to the Tri-Core Fabric 1. Further, theSingle-Core Fabric 1 did not meet industry standards for recovery ofdenim, which are set at 85%. Even further, the width of the Single-CoreFabric 1 was smaller than the width of the Tri-Core Fabric 1.

In addition, the Tri-Core Fabric 1 according to the first examplerequires 67% less energy to stretch as compared to the Dual-CoreFabric 1. As such, the Tri-Core Fabric 1 including the tri corecomposite yarn typically feels less restrictive as compared to theDual-Core Fabric 1 including the dual core yarn, yet it may stillprovide characteristics of shapewear fabrics.

Even further, the prorated cost of fabrication of the Tri-Core Fabric 1including the tri core composite yarn provides a cost savings ofapproximately 5% as compared to the Single-Core Fabric 1 including thesingle core yarn and a cost savings of approximately 12% compared to theDual-Core Fabric 1, while the Dual-Core Fabric 1 including the dual coreyarn requires an 8% cost increase as compared to the Single-Core Fabric1 including the single core yarn.

A table relating to Example 1 is provided below:

TABLE 1 Recovery Weft Width Stretch (% After Shrinkage Relative FabricWarp (Denier) (In.) (%) 30 mins.) (%) Cost Tri-Core 12 SB 21s 30D 52.574 85.6 12-14 1.0 Fabric 1 Nylon, 30D Nylon, 70D FIBERJ® Dual-Core 12 SB21s 75D 49.5 71 87.9 13-15 1.12 Fabric 1 T400®, 40D LYCRA® Single-Core14 Even 21s 70D 51 82 81.2 22-24 1.05 Fabric 1 LYCRA®

EXAMPLE 2

In Example 2, 40 denier spandex was used as the elastomeric fiber, 50denier polyester was used as the first wrapping fiber, and 50 denierpolyester was used as the second wrapping fiber to form a tri-corecovered core yarn.

The tri-core covered core yarn was then core spun using a single corespinning apparatus to produce a tri-core composite yarn. To produce afabric (Tri-Core

Fabric 2), C16 (Ne 1/16) of this tri-core yarn was used for the weft,and 10 SB (Ne 10/1 slub) for the warp. This produced the Tri-Core Fabric2 having a width of 56 inches, and a weight before wash of 9 ounces persquare yard and a weight after wash of 10.4 ounces per square yard.

Using the Tri-Core Fabric 2 having the tri-core composite yarn describedabove, the Tri-Core Fabric 2 exhibited a stretch of 40%, recovery of 78%30 seconds after stretching and 83% 30 minutes after stretching, growthof 8.8% 30 seconds after stretching and 6.8% 30 minutes afterstretching, and 13-15% shrinkage.

In a similar trial of a dual-core yarn as is known in the art (aDual-Core Fabric 2), a dual-core yarn having a first core of 75 denierT400® and a second core of 40 denier spandex were used. In particular,the Dual-Core Fabric 2 was prepared with a warp of 10 and a weft of C16of the dual-core yarn described above. This produced the Dual-CoreFabric 2 having a width of 56 inches, and a weight before wash of 8.8ounces per square yard and 10.4 after wash ounces per square yard.

Using the Dual-Core Fabric 2 having the dual-core yarn described above,the Dual-Core Fabric 2 exhibited a stretch of 37.6%, recovery of 71.3%30 seconds after stretching and 78.7% 30 minutes after stretching,growth of 10.8% 30 seconds after stretching and 8.0% 30 minutes afterstretching, and 13-15% shrinkage. The cost to prepare the Dual-CoreFabric 2 was approximately 2% higher than the cost to prepare theTri-Core Fabric 2.

In a similar trial of single core yarn as is known in the art (aSingle-Core Fabric 2), a single-core yarn having a 40 denier spandexcore was used. In particular, the Single-Core Fabric 2 was prepared witha warp of 10 SB and a weft of C16 with the 40 denier spandex core. Thisproduced the Single-Core Fabric 2 having a width of 55 inches, and aweight before wash of 9.2 ounces per square yard and 10.5 after washounces per square yard.

Using the Single-Core Fabric 2 having the single core yarn describedabove, the Single-Core Fabric 2 exhibited a stretch of 33.6%, recoveryof 65.5% 30 seconds after stretching and 75% 30 minutes afterstretching, growth of 11.6% 30 seconds after stretching and 8.4% 30minutes after stretching, and 13-15% shrinkage. The cost to prepare theSingle-Core Fabric 2 was approximately 2% lower than the cost to preparethe Tri-Core Fabric 2.

As demonstrated by the above results, although the Single-Core Fabric 2exhibited similar shrinkage characteristics as compared to the Tri-CoreFabric 2, the Single-Core Fabric 2 exhibited 16% less stretch anddecreased recovery (16% less recovery after 30 seconds and 10% lessrecovery after 30 minutes) as compared to the Tri-Core Fabric 2.

Similarly, although the Dual-Core Fabric 2 exhibited similar shrinkagecharacteristics as compared to the Tri-Core Fabric 2, the Dual-CoreFabric 2 exhibited 6% less stretch and decreased recovery (9% lessrecovery after 30 seconds and 5% less recovery after 30 minutes) ascompared to the Tri-Core Fabric 2.

Even further, the cost of fabrication of the Tri-Core Fabric 2 includingthe tri core composite yarn provides a cost savings of approximately 2%compared to the Dual-Core Fabric 2, while the Dual-Core Fabric 2including the dual core yarn requires a 4% cost increase as compared tothe Single-Core Fabric 2 including the single core yarn.

A table relating to Example 2 is provided below:

TABLE 2 Growth Recovery Weft Stretch (% After (% After ShrinkageRelative Fabric Warp (Denier) (%) 30 mins.) 30 mins.) (%) Cost Tri-Core10SB C16 50D 40 6.8 83 13-15 1.0 Fabric 2 Nylon, 50D Nylon, 40D SpandexDual- 10SB C16 75D 37.6 8.0 78.7 13-15 1.02 Core T400®, 40D Fabric 2Spandex Single- 10SB C16 40D 33.6 8.4 75 13-15 0.98 Core Spandex Fabric2

While this disclosure has been described in detail with particularreferences to some exemplary embodiments thereof, the exemplaryembodiments described herein are not intended to be exhaustive or tolimit the scope of the disclosure to the exact forms disclosed. It isunderstood that the drawings are not necessarily to scale. Personsskilled in the art and technology to which this disclosure pertains willappreciate that alterations and changes in the described structures andmethods of assembly and operation can be practiced without meaningfullydeparting from the principles, spirit, and scope of this disclosure, asset forth in the following claims and their equivalents.

What is claimed is:
 1. A tri-core yarn comprising: a core comprising: anelastomeric filament; a first cover; and a second cover; and a fibersheath covering the core, wherein the first cover and the second coverare each wrapped around the elastomeric filament.
 2. The yarn of claim1, wherein the first cover is wrapped in a first direction and thesecond cover is wrapped in a second direction.
 3. The yarn of claim 1,wherein the elastomeric filament, the first cover, and the second coverare twisted together.
 4. The yarn of claim 1, wherein the first coverand the second cover are different materials.
 5. The yarn of claim 1,wherein the elastomeric fiber is in a range of about 10 denier to about300 denier.
 6. The yarn of claim 1, wherein the first cover comprisespolyester or nylon.
 7. The yarn of claim 6, wherein the first cover ispartially oriented yarn or fully drawn yarn.
 8. The yarn of claim 1,wherein the first cover is in a range of about 10 denier to about 600denier.
 9. The yarn of claim 1, wherein the core is in a range of about10 denier to 600 denier.
 10. The yarn of claim 1, wherein the fibersheath comprises cotton, polyester, viscose, rayon, modal, lyocell,cupro, nylon, acrylic, wool, linen, hemp, ramie, and/or polyethylene.11. The yarn of claim 1, wherein the first cover yarn is wrapped aroundthe elastomeric filament and the second cover yarn is wrapped around thefirst cover yarn.
 12. A method of manufacturing yarn, the methodcomprising: covering an elastomeric filament with a first cover yarn anda second cover yarn to form a core; core-spinning the core to add afiber sheath.
 13. The method of claim 12, wherein the covering of theelastomeric filament comprises: wrapping the first cover yarn around theelastomeric filament in a first direction; and wrapping the second coveryarn around the elastomeric filament in a second direction.
 14. Themethod of claim 12, wherein the covering of the elastomeric filamentcomprises intermingling or air-covering the elastomeric filament withthe first cover yarn and the second cover yarn.
 15. The method of claim12, wherein the covering of the elastomeric filament comprises aligningthe elastomeric filament, the first cover yarn, and the second coveryarn and twisting the elastomeric filament, the first cover yarn, andthe second cover yarn together.
 16. A stretch fabric comprising a yarn,the yarn comprising: a core comprising: an elastomeric filament; a firstcover; and a second cover; and a fiber sheath covering the core, whereinthe first cover and the second cover are each wrapped around theelastomeric filament.
 17. The stretch fabric of claim 17, wherein a weftand a warp of the fabric comprise the yarn.
 18. The stretch fabric ofclaim 16, wherein the fabric comprises plain, poplin, twill, oxford,dobby, sateen and/satin fabric.
 19. The stretch fabric of claim 16,wherein the stretch fabric is configured to be stretched to between 10%and 100% of its original size in a warp direction.